Methods of and apparatus for packaging longitudinal material



Filed May 23, 1966 Sheet April 22, 1969 w. B. anbww 3,439,483

METHODS OF AND APPARATUS FOR PACKAGING LONGI'I'UDINAL MATERIAL FIG/ lNVE N TOR A 7' TORNEY W8. BROWN April 22, 1969 w. B. BROWN METIIODS OF AND APPARATUS FOR PACKAGING LONGITUDINAL MATERIAL Filed May 23, 1 966 A ril 22, 1969 w. 9. BROWN 3, ETHODS OF AND MPARATUS FOR PACKAGING LONGITUDI NAL MATERIAL Filed i 2a. 1966 shm 3 o! 6 April 22, 1969 w. s. snows:

METHODS OF AND APPARATUS FOR PACKAGING Filed lay 23, 1966 I LONGITUDINAL MATERIAL sheet ,m wt

mm a, 23, 1966 April 22, 1969 v 1 "ETHODS OF AND APPARATUS FOR PACKAGING LONQITU DINAL IATERIAL v A Shoot 91 6 A waJanowu 3,439,483

April 22, 1969 w. B. BROWN "muons OF AND APPARA LONGITUDINAL 'r'us FOR PACKAGING MATERIAL Sheet 6 of s Filed Hay 23, 1966 xwt I Jlllllll U.S. Cl. 57-6 United States Patent 3,439,483 METHODS OF AND APPARATUS FOR PACKAGING LONGITUDINAL MATERIAL William B. Brown, Pasadena, Md., assignor to Western Electric Company, Incorporated, New York, N.Y., a corporation of New York Filed May 23, 1966 Ser. No. 552,335 Int. Cl. D02g 3/36 16 Claims ABSTRACT OF THE DISCLOSURE Methods of and apparatus for packaging different proportional lengths of longitudinally extending material onto a plurality of take-up unitsand thereafter wrapping the 'the diameter of the associated roll whereby the length of material taken up on one reel differs from the length taken up on another reel during a given period. The differential gear mechanism facilitates the different rates of rotation of the reels. The full reels are then used to wrap the different lengths of material, one on top of the other, helically about a moving core whereby the different reels of the predetermined different lengths of material deplete simultaneously.

This invention relates to methods of and apparatus for packaging longitudinal material and relates more particularly to methods of and apparatus for packaging simultaneously different proportional lengths of longitudinal material in separate units.

One type of coaxial cable unit, as disclosed in United States Patent 2,471,299, which issued to E. Bertalan et al., on May 24, 1949, includes a central conductor and a plurality of slotted discs positioned on the central conductor for insulating the center conductor from an outer tubular conductor and for spacing the outer conductor coaxially of the center conductor. A pair of overlapping steel tapes are wrapped helically about the outer tubular conductor to provide strengthening, flexibility and shielding characteristics for the unit. Frequently, a plastic insulation is placed over an individual coaxial cable unit subsequent to the wrapping of the steel tapes about the outer tubular conductor, or a plurality of units and other types of conductors may be stranded together and sheathed to complete the assembly of a multiunit coaxial cable. i

To facilitate the wrapping of the steel tapes about the outer tubular conductor, a taping head, such as that disclosed in United States Patent 3,178,878, which issued to W. B. Brown on Apr. 20, 1965, was used to support individual supply reels with the axes of the reels being parallel and spaced from the axis of a coaxial cable unit. During the tape-wrapping operation, the taping head is rotated about the axis of an advancing coaxial cable unit so that the supply reels are orbited about the coaxial cable unit and rotated about their individual axes whereby the individual steel tapes are drawn from the supply reels and wrapped, one on top of the other, helically about the outer tubular conductor of the coaxial cable unit.

Since one steel tape was wrapped about the other steel tape, one tape will be longer than the other and an addi- 3,439,483 Patented Apr. 22, 1969 tional length of tape is required from the supply reel which furnishes the tape for the outer wrapping.

The taping head, in the manufacture of the coaxial cable, required a considerable mass to support the supply reels of the steel tape and, hence, balancing problems resulted. As disclosed in the U.S. Patent 3,178,878 to W. B. Brown, the balancing problems were minimized by a dynamic balancing system. However, the dynamically balanced system still required the orbiting of the reels as well as movement of a considerable mass to effect the tape wrapping. Further, the steel tape had to be individually packaged on each supply reel, in accordance with the length demands of the inner and outer layer of the tape wrappings, at some location distant from the taping head and then transported and secured to the taping head. This procedure was necessary to ensure that the tape supplies would deplete simultaneously during the wrapping operation so that short lengths of scrap tape would not remain on one reel as the supply of the other reel became depleted.

In addition to the foregoing, the steel tapes were packaged on reels of relatively small diameters to facilitate handling and to limit the size of the taping head necessary for supporting the reels during the tape-wrapping operation. During the tape-packaging operation, the tape was distributed on the small reels. Due to the small diameter of the reels and the width of the tapes, buckling of the tape sometimes resulted adjacent to the flanges of the reel as the distribution of the tape was reversed.

A braking force was applied to each of the reels on the taping head and varied during the wrapping operation to compensate for the decreasing package size. In addition, a constant drawing force was applied to each of the tapes for drawing individually the tapes from the associated reels thereby maintaining a constant tension on each of the tapes between the associated reels and the outer tubular conductor. As a buckled section of the tape was drawn from the associated reel, a slack developed in the tape between the reel and the outer tubular conductor thereby decreasing the drawing force applied to the tape to draw the tape from the associated reel. Since the drawing force was decreased, the braking force applied to the reel caused the reel to rotate at a reduced speed.

After the slack portion of the tape had been wrapped around the outer tubular conductor, the force for drawing the tape from the associated reel returned to the normal level. As the drawing force returned to the normal level, a jerking action resulted in the tape as a result of the force required to reaccelerate the reel to the previous rotational speed. As the jerking action in the wrapping operation occurred, the tape was drawn tightly infrequently onto the outer tubular conductor which could alter detrimentally the concentric configuration of the outer tubular conductor and affect adversely the electrical characteristics of the coaxial unit.

Hence, while the problems of balancing the taping head may be minimized in the manner taught by US. Patent 3,178,878 to W. B. Brown, the steel tape still had to be packaged individually separately, in accordance with length requirements, at some location distant from the taping head. Further, the buckling of the tape on the small reels of the tape packages may affect adversely the final product unless the tension is controlled very accurately.

It is, therefore, an object of this invention to provide new and improved methods of and apparatus for packaging different lengths of longitudinal material.

Another object of this invention is to provide new and improved methods of and apparatus for packaging simultaneously, proportional lengths of longitudinal material in different packages.

Still another object of this invention is to provide new and improved methods of and apparatus for packaging simultaneously, individually, separate proportional lengths of longitudinal material onto packaging units supported axially coincidentally about a moving core so that different lengths of material are packaged on the units which do not have to be supported on a taping head, are of sufficient size to preclude buckling of the material distributed on the units whereby a constant tension on the tapes can be maintained and are supported in a prearranged order to facilitate a subsequent wrapping of the material about the core in a prescribed manner.

A further object of this invention is to provide new and improved methods of and apparatus for packaging simultaneously, individually, separate proportional lengths of longitudinal material onto packaging units supported axially coincidentally about a moving core so that different lengths of material are packaged on the units which do not have to be supported on a taping head, are of sufficient size to preclude buckling of the material distributed on the units whereby a constant tension can be maintained on the tapes and are supported in the prearranged order and for Withdrawing the separately packaged lengths of longitudinal material from the packaging units of the prearranged order and wrapping helically the lengths of material about the moving core so that successive lengths of the material are wraped on top of preceding lengths whereby the differentially packaged lengths of longitudinal material of the prearranged order are depleted simultaneously.

A method illustrating certain features of the present invention may include the steps of supplying indefinite lengths of longitudinally extending material to material packaging units, and maintaining simultaneously predetermined proportionately different rates of feed of a plurality of individual lengths of the longitudinally extending material to a plurality of different packaging units so that, at any one instance, proportionately different lengths of the longitudinally extending material are taken up in the different packaging units.

Apparatus illustrating certain features of the invention may include means for supplying indefinite lengths of longitudinally extending material and means for maintaining simultaneously predetermined proportionately different rates of feed of a plurality of individual lengths of the longitudinally extending material to a plurality of different packages so that, at any one instance, proportionately different lengths of the longitudinally extending material are taken up in the different packages.

Other objects and advantages of the invention will appear from the following detailed description of a specific embodiment thereof when read in conjunction with the appended drawings in accordance with the principles of the invention, in which:

FIG. 1 is a front view showing a coaxial unit forming machine;

FIG. 2 is a perspective view showing the assembled elements of a coaxial unit;

FIG. 3 is a perspective view showing a tape rewinder for winding different lengths of longitudinal material onto separate packages in accordance with the principles of the invention and further showing facilities for wrapping steel tape about a moving coaxial unit;

FIG. 4 is a plan view taken along line 44 of FIG. 1 showing the tape rewinder and the tape-wrapping facilities with sections broken away for clarity;

FIG. 5 is a front view taken along line 55 of FIG. 4 showing the tape rewinder with sections broken away for clarity and for further showing the tape-wrapping facilities,

FIG. 6 is a sectional view taken along line 66 of FIG. 5 showing a distributing mechanism for distributing the longitudinal material onto a plurality of packaging units, and

FIG. 7 is a sectional view taken along line 77 of FIG. 4 showing the tape-wrapping facilities.

Referring to FIG. 2, one type of a coaxial assembly includes a center conductor 22, a plurality of slotted insulating discs 24-24 positioned spatially concentrically on the center conductor and an outer tubular conductor 23 with the discs positioned to facilitate a spacing between the center conductor and the outer tubular conductor with their axes concentric. The outer tubular conductor 23 is formed from a longitudinal tape 20 having tabs 26-26 formed spatially along and extending transversely from the edges of the tape. As the longitudinal tape 20 is folded into the tubular configuration to form the outer conductor 23, the tabs 2626 formed on the opposing edges of the tape are interwoven between the spaced tabs of the opposite edge to lock the tape in the tubular configuration. Thereafter, a pair of steel tapes 2727 are helically wrapped about the outer tubular conductor 23 to form a coaxial unit 21 and, further, to provide flexibility, strength and shielding properties for the coaxial unit.

. GENERAL DESCRIPTION Coaxial unit forming machine As shown in FIG. 1, portions of a coaxial unit forming machine, designated generally by the reference numeral 28, for forming the coaxial unit 21 are similar generally to a coaxial unit forming machine disclosed in US. Patent 2,471,299 and will, therefore, not be discussed in detail herein.

Referring further to FIG. 1, a supply stand 29 is supported on a floor level 31 and supports rotatably a supply reel 32. A supply of the center conductor 22 extends from the supply reel 32 and is passed over a sheave 33 which is supported on a bracket 32 extending from the supply stand 29. A tension arm 36 is secured pivotally at one end thereof to the supply stand 29 and supports for rotation a guide sheave 37 at the opposite end thereof. The center conductor 29 is passed partially over the sheave 37 and into a disc applicator housing, designated generally by the reference numeral 38, which is supported on a pedestal 39 mounted on the floor level 31. A pair of opposed disc applicator wheels 4141 are supported for rotation within the housing 38 where the center conductor 22 is passed between the opposed applicator wheels to facilitate the application periodically of'the slotted discs 2424 onto the center conductor. The physical facilities for effecting the application of the discs 2424 onto the center conductor 22 is similar to the disc application facilities disclosed in US. Patent 2,471,299.

The center conductor 22 supporting the spaced slotted discs 2424 is then moved into a housing, designated generally by the reference numeral 42, which is supported on the pedestal 39 and houses apparatus for folding the longitudinal tape 20 about the spaced discs 2424 to form the outer tubular conductor 23. Included within the housing 42 is a supply reel 43 for supplying the longitudinal tape 20 to a tube-forming device, designated generally by the reference numeral 44. The physical facilities for forming the tubular conductor 23 are similar to the facilities disclosed in US. Patent 2,471,299. The assembly of the center conductor 22, the spaced discs 2424 and the outer tubular conductor 23 is passed through a bearing support housing, designated generally by the reference numeral 46, which is supported on a pedestal 47. The assembled center conductor 22, outer tubular conductor 23, and the spaced discs 2424 are passed through a steel tape-wrapping device, designated generally by the reference numeral 48, to facilitate the wrapping of the steel tapes 2727 about the outer tubular conductor to form the coaxial cable 21 as shown in FIG. 2.

The coaxial unit 21, having the steel tapes 2727 wrapped helically therearound, is passed through a differential tape rewinder, designated generally by the reference numeral 49, which facilitates the packaging of the steel tapes 2727 for subsequent tape-wrapping opera- DIFFERENTiAFTAPE Rawinnisn whi ch' packages eel tapes 2727 27 are packaged in different packages. I

rapped about adjacent to the area wh the moving outer tub'ulaircon' tion of the packagedtapes Specifically, the differenin FIGS. 3, 4 and 5,"includes g tends upwardly from the fl oo level A'beari'ng support 57 extends horizontallyffro' H A "ediatefportion of the stand 56 and supportsh r'iz many rionro'tatable shaft 58 which extends on opposite o the bearing support. A pair of conventional bl' re supports 59-59 (FIG. 3) are mounted 'fo r rota ln'"*o"pposite ends of the shaft 58 for supporting a panof supplyreels 6161. It is noted that the supply; reels 614 61 supply the steel tapes 27-27 to theditferential tape rewin'der 49 and therefore do not have to be efinedle ngth prior to the differential rewinding operation. I j

Referring to FIG. 3, and particularly to FIG. a braking device, designated genrallybythe' reference numeral 62, includes a constant brake mechanism (not shown) mounted Within the housing which is supported on an arm 64 extending laterally fromthe vertical stand 56. One end of a solid shaft 66 is positi oned within the housing 63 in engagement with the'brake mechanism to place a constant dragging force on the shaft when the shaft is rotated. The shaft 66 extends from the housing 63 and is supported intermediately for rotation by a bearing 67 in the housing 63 and is supported at the opposite end thereof for rotation by a bearing (not shown) in a bearing housing 68 which is supported on an arm '70 extending laterally from the vertical stand 56.

A differential gear mechanism, designated generally by the reference numeral 69, includes a pair of bevelled pinions 71 and 72 which are mounted spatially for rotation about a common axis on opposite ends of a spider 73. The spider 73 is keyed to an intermediate portion of the shaft 66 to facilitate orbiting of the pinions 71 and 72 about the axis of the shaft during rotation of the shaft. The differential gear mechanism 69 also includes a pair of bevel gears 74 and 76 which are mounted spatially axially on the shaft 66 for free rotation relative to the shaft. The pinions 71 and 72 of the differential gear mechanism 69 are meshed with the spaced gears 74 and 76.

A pulley 77 is mounted axially on the shaft 66 for free rotation with respect to the shaft and is secured to the gear 74 for rotation with the gear about the axis of the shaft. A pulley 78 is mounted axially on the shaft 66 for free rotation relative to the shaft and is secured to the gear 76 for rotation with the gear. The pulleys 77 and 78 are mounted spatially axially on the shaft 66 on opposite sides of the differential gear mechanism 69. A pair of collars 79 and 81 are mounted spatially axially on the shaft 66 for rotation with the shaft. The pulleys 77 and '78 and the differential gear mechanism 69 are'positioncd between the collars 79 and 81 to preventfthe pulleys and the gear mechanism from moving axially' on the shaft.

The pulley 77 is positioned spatially vertically above a pulley 82 which is coupled to tthe e xpandable reel support 59, shown to the rightinFIGSJ-B"and5, and is mounted on the shaft 58 for'rotationwith the associated reel support about the shaft. An endless belt 83 is positioned around the spaced pulleys 77 and 82 so that the rotational movement of the reel 61, shown to the right in FIGS. 3 and 5, results in the rotation of the pulley 77. The pulley 78 is positioned spatially vertically above a pulley 84 which is coupled to the expandable reel support 59, shown to the left in FIG. 3, and is mounted on the shaft 58 for rotation With the associated reel support about the shaft. An endless belt 86 is positioned around the space pulleys 78 and 84 so that the rotational movement of the reel 61, shown to the left in FIGS. 3 and 5, results in the rotation of the pulley 78.

Generally, when the steel tapes 27-27 are pulled from the associated supply reels 6161 at the same rate, the rotational speed of the reels will be the same. This rotational movement is transferred to the pulleys 77 and 78, respectively, through the pulleys 82 and 84, respectively, and the endless belts 83 and 86, respectively. As the pulleys 77 and 78 rotate at the same speed, the bevel gears 74 and 76, respectively, rotate freely about the shaft 66 with the pulleys at the same rotational speed. Since there is no difference between the rotational speeds of the bevel gears 74 and 76, the pinions 71 and 72 will not rotate about their common axis but will orbit about the axis of the shaft 66 with the rotational force being transmitted from the gears 74 and76 to the pinions 71 and 72. Since the spider 73, which links spatially the pinions 71 and 72, is keyed to the shaft 66, the shaft is rotated by the action of the differential gear mechanism 69.

The brake mechanism within the housing 63 exerts a dragging force upon the shaft 66 as the shaft is rotated so that the total dragging force is equally divided between the pulleys 77 and 78. The braking force on the rotating shaft 66 results in the application of equal torque to the reels 6161 as the steel tapes 2727 are drawn from the associated supply reels.

When the steel tape 27 being drawn from the associated reel 61, which is shown to the right in FIG. 5, is drawn at a rate faster than the rate at which the steel tape is being drawn from the other reel, the pulley 77 will rotate at a rate faster than the rate of rotation of the pulley 78. As the rate of rotation of the pulley 77 in creases, the gear 74 will rotate about the axis of the shaft 66 at a rate faster than the rate of rotation of the gear 76. Due to the difference in the rates of rotation of the gears 74 and 76, the bevelled pinions 71 and 72 will rotate about their common axis as well as continue orbiting about the axis of the shaft 66. This response by the differential gear mechanism 69 to the difference in the rates at which the steel tapes 27 are being withdrawn from the associated supply reels 61-61 permits the dragging force exerted upon the shaft 66 by the brake mechanism within the housing 63 to continue to be equally divided between the pulleys 77 and 78. The equally divided dragging force, exerted upon the rotating shaft 66 by the brake mechanism, facilitates the continued application of equal torque to the reels 61-61 as the steel tapes 2727 are being drawn from the associated supply reels regardless of the difference in the rates at which the tapes are being drawn from the associated reels.

As shown in FIGS. 3, 4 and 5, a pair of guide sheaves 92 and 93 are supported on a sheave: support bar 94 which is mounted on an arm 96 (FIG. 4) extending laterally outwardly from an intermediate portion of the vertical stand 56. A second set of sheaves 97 and 98 are supported spatially for rotation on the free ends of a pair of arms 99 and 190, respectively, supported by an extension bar which extends laterally from the top of the vertical stand 56.

Difierential unit Referring to FIGS. 3 through 6, a gear housing 101, which houses driving facilities for the packaging of the steel tapes 27-27, is supported on a table 102 which is mounted on the floor level 31. A cam housing 103, which houses reciprocating facilities for the distribution of the steel tapes 27-27 during the packaging operation, is mounted on top of the gear housing 101 and supports a reciprocable rod 104 which extends slidably therefrom. A support arm 106 is secured to and extends laterally from the free end of the rod 104 and supports vertically a roll mounting support 107. A shaft 108 (FIG. 6) is supported for rotation in a lower portion of the mounting support 107 and extends on opposite sides of the support. A sheave-like roll 109 is mounted on one end of the shaft 108 for rotation with the shaft which extends on the left side of the mounting support 107, as viewed in FIG. 5. The roll 109 is formed peripherally with a plurality of spaced annular grooves 111-111 with the width of each groove being sufficient to facilitate passage longitudinally of the steel tape 27 through the grooves.

Another sheave-like roll 112 is mounted on the opposite end of the shaft 108 for rotation with the shaft. The roll 112 is formed peripherally with a plurality of spaced annular grooves 113-413 sufficiently wide to facilitate passage longitudinally of the steel tape 27 through the grooves. It is noted that the pitch diameter of the grooves 111-111 of the roll 109 is greater than the pitch diameter of the grooves 113113 of the roll 112. Since both rolls 109 and 112 are mounted commonly on the shaft 108, both rolls will have the same angular velocity. However, due to the difference in the pitch diameters of the grooves 111-111 and 113-113 of the rolls 109 and 112, respectively, the rate at which the steel tapes 27-27 pay out from the associated roll will differ in proportion to the difference in the pitch diameters of the grooves of the associated rolls. For example, since the pitch diameter of the grooves 111-111 of the roll 109 is larger than the pitch diameter of the grooves 113113 of the roll 112, the rate of pay out of the steel tape 27 from the roll 109 will be greater than the rate of pay out of the steel tape 27 from the roll 112 in proportion to the ratio of the dif ference between the pitch diameters of the grooves of the associated rolls. It is noted that the rolls 109 and 112 could be formed as a single element having sections with different diameters.

A shaft 114 extends laterally from an upper portion of the mounting support .107 and supports a canted idler sheave 116 which is positioned spatially above the roll 109 and is formed with a plurality of spaced, peripheral grooves 117117 of sufficient width to facilitate passage of the steel tape 27 through the grooves. The idler sheave 116 is canted with respect to the roll 109 to facilitate guiding movement of the steel tape 27 over the aligned grooves 117117 and 11\1111 of the spaced idler sheave and roll, respectively. In this manner the steel tape 27 is passed partially over the idler sheave and the spaced roll several times and passes successively over adjacent grooves 111- 111 and the roll 109 and adjacent grooves 117117 of the idler sheave 116, respectively. The steel tape 27 is guided thereby into an entry groove 111a in the roll 109, around the spaced roll and idler sheave .116 and from an exit groove 1t11b in the roll to the packaging facilities.

A shaft 118 (FIG. 4) extends laterally from the upper portion of the opposite side of the mounting support 107 and supports a canted idler sheave 119 for rotation on the shaft. The idler sheave 118 is mounted spatially above the roll 112 and is canted with respect to the roll so that a plurality of spaced, peripheral grooves 121-121 formed in the idler sheave are aligned properly with the plurality of spaced peripheral grooves 1 13113 of the roll to facilitate the guiding of the steel tape 21 into an entry groove 113a in the roll, around the spaced roll and idler sheave 119 and from an exit groove 1131b in the roll.

It is noted that the idler sheaves 116 and 119 are mounted individually of each other on separate sheaves 1'14 and 118, respectively. The idler sheaves 116 and .119 provide a capstan effect for the steel tapes 2727 which pass partially around the rolls 109 and 112, respectively, and

limit the amount of slippage between the steel tapes and the associated rolls so that the length of tape paying out from each of the rolls is proportional accurately to the pitch diameter of the associated roll.

Packaging units Referring to FIGS. 3 and 4, and particularly to FIG. 5, a tubular shaft 122 extends horizontally from the gear housing 101 and is supported for rotation by a bearing 123 in the gear housing.- The shaft 122 is hollow axially to facilitate movement axially of the coaxial unit 21 through the tape rewinder 49. This feature permits a tape rewinding operation to beeffected simultaneously with a coaxial unit forming operation. One end of the tubular shaft 122 is connected to a gear mechanism (not shown) within the housing l0l which" facilitates the rotation of the tubular shafL-A pair ofconventional expandable reel supports 124 and 126 are mounted spatially on the tubular shaft 122 for rotation relative to the shaft. A pair of collars 127 and 128 are secured spatially on the tubular shaft 122 for rotation with ihe shaft to retain the spaced expandable reel supports-124 and 126 within a confined space with the reels'floating on the shaft and free to rotate about the shaft. f j

A differential gear mechanism, designated generally by the reference numeral '1'29,'in'c1udes a pair of axially spaced, bevelled piniohs 131 and 132, respectively, and a pair of axially spaced bevel gears 133 and 134, respectively. The pinions 131- and 132 of the differential gear mechanism 129 are spaced axially apart and are secured to one end of a pair of pins 130 and 135, respectively, to facilitate individual rotation of each gear about their own axis. The opposite ends of the pins 130 and are keyed to the tubular shaft 122 for rotation with the shaft so that the pinions 131 and 132, respectively, may be orbited about the axis of the tubular shaft. The bevel gears .133 and 134 are spaced axially and are secured to the expandable reel supports 12 4 and 126, respectively, for rotation with the supports. As shown in FIG. 5, the pinions 131 and 132 of the differential gear mechanism 129 mesh with the bevel gears 133 and 134. Outer hub portions of the expandable reel supports 124 and 126 extend toward each other to enclose substantially the differential gear mechanism 129 within a protective enclosure.

R-eferring now to FIGS. 4 and 5, and particularly to FIG. 3, a pair of split reel sections 136 and 137 are each formed with a complementary notched configuration shown generally at 138. In assembling the split reel sections 136 and .137, the sections are positioned about a common axis with the flanges of the reel being slightly offset. The split reel sections 136 and 137 are then moved axially towards each other so that the complementary notched configuration at 138 facilitates the joining of the split reel sections to form a steel tape packaging unit, such as a reel, designated generally by the reference numeral 139. The complementary notched configuration at 138 precludes radial separation of the split reel sections 136 and 137 subsequent to the assembling of the sections.

In order to mount the reels 139139 onto the expandable reel supports 124 and 126, a pair of the complementary split reel sections 136 and .137 are positioned about each of the expandable reel supports with one split section of each pair being slightly offset from the associated split section. The associated split reel sections 136 and 137 of each pair are then moved axially towards each other to form the pair of reels 139139 as shown in FIGS. 3, 4 and 5. The split reel sections 136 and 137 are thereby precluded from separating radially from each other due to the locking feature of the complementary notched configuration at 138. The conventional expandable reel supports 124 and 126 are adjusted to move expandable elements (not shown) into engagement with the inner walls of the assembled reels 139--139 so that the reels are supported on and will rotate with the expandable reel supports. It is noted that the reel support 124 supports one of the reels 139-139 in a tape packaging position spatially beneath the differential roll 109 and the reel support 12-6 supports the remaining reel in a tape packaging position spatially beneath the differential roll 112.

Distributor for the differential unit Referring to FIGS. 3, 4 and 5, and particularly to FIG. 6, a distributor mehanism, designated generally by the reference numeral 141, facilitates the reciprocation of the rolls 109 and 112 along their common axis so that steel tapes 27-27 paying out from the rolls are distributed onto the supported, associated reels 139-139 in the packaging position. The distributor 141 includes a gear housing-142 supported on top of the gear housing 101 adjacent to the cam housing 103. A rotatable shaft 143 is connected at one end thereof to a gear mechanism (not shown) within the gear housing 142. The shaft 143 extends from the gear housing 142 and into the cam housing 103. An intermediate portion of the shaft 143 is supported by a bearing 144 mounted in the cam housing 103 and is connected at the opposite end thereof to a earn 146 within a cam chamber 147 of the cam housing.

The reciprocable rod 104 is slidably positioned within a slide chamber 149 of the cam housing 103. A cylinder 151 is mounted axially at one end of the slide chamber 149 and has a constant pressure applied thereto through an inlet line 150. A piston rod 152 extends from the cylinder 151 into the slide chamber 149 and is urgedconstantly to a withdrawn position within the cylinder due to the constant pressure applied to the cylinder. The free end of the piston rod 152 is connected to one end of the rod 104 for urging constantly the rod to the right as viewed in FIG. 6.

A slot 153 is formed in a portion of the cam housing 103 to facilitate communication between the cam chamber 147 and the slide chamber 149. A roller 154 is mounted for rotation on a stud 155 which extends laterally from the rod 104 and through the slot 153 so that the roller is positioned adjacent to and in engagement with the peripheral surface of the cam 146 within the cam chamber 147. As noted previously, the rod 104 extends from the slide chamber 149 and is connected at the opposite end thereof to the support arm 106 which supports the roll mounting support 107.

To facilitate the reciprocation of the differential rolls 109 and 112, a constant pressure is applied to the cylinder 151 to urge the rod 104 to the right as viewed in FIG. 6 so that a force is constantly attempting to draw the rod within the slide chamber 149. However, the roller 15 is in engagement with a portion of the periphery cam 146 which precludes complete withdrawal of the rod 104 to a position within the slide chamber 149. As the gear mechanism within the gear housing 142 is driven, the shaft 143 is rotated to facilitate rotation of the cam 146 so that the cam surface facilitates movement of the roller 154 laterally to the left, as viewed in FIG. 6, with respect to the roller axis thereby imparting axial movement to the rod 104. When the cam 146 no longer urges the roller 154 to the left, the constant pressure on the cylinder 151 draws the piston rod 152 to the right. The cooperative action between the cam 146 and the cylinder 151 imparts a reciprocating motion to the rod 104. As the rod 104 is reciprocated, the differential rolls 109 and 112 are reciprocated axially to facilitate the distribution of the steel tapes 27-27 onto the associated reels 139-139.

Driving system for difierential rewinder Referring now to FIGS. 3, and 6, and particularly to FIG. 4, a driving system for imparting motion to the driven elements of the differential tape rewinder 49 includes an electric motor 156 which is mounted on the table 102. A shaft 157 extends from the motor 156 and is coupled to the motor for rotation. The shaft 157 extends into the gear housing 101 and is coupled at the opposite end thereof to the gear mechanism within the housing.

As previously noted, the tubular shaft 122, as viewed particularly in FIG. 5, is connected at one end thereof to the gear mechanism within the gear housing 101. When the motor 156 is operated, the gear mechanism within the gear housing 101 is controlled to impart a rotational force to the shaft 122 so that the pinions 131 and 132 of the differential gear mechanism 129 are orbited about the axis of the tubular shaft 122. The orbiting of the pinions 131 and 132 about the axis of the tubular shaft 122 imparts rotational movement to the bevel gears 133 and 134 and, consequently, to the expandable reel supports 124 and 126, respectively. Since the reels 139-139 are assembled on the rotatable reel supports 124 and 126, the reels will also rotate about the common axis of the tubular shaft 122 to facilitate the packaging of the steel tapes 27-27 by drawing the tapes from the associated supply reels 61-61 and over the rolls 109 and 112.

As viewed in FIG. 4, a shaft 158 extends from the gear housing 101 and is connected at one end thereof to the gear mechanism in the housing. The opposite end of the shaft 158 is connected to a sprocket wheel 160 (FIG, 3). A shaft 159 extends from the gear. housing 142 and is coupled at one end thereof to the gear mechanism within the housing. The opposite end of the shaft 159 is coupled to a sprocket wheel (FIG. 3) spaced from but in the same plane as the sprocket wheel 160. An endless chain 161 is positioned around the sprocket wheels 160 and 165 which are mounted on the shafts 158 and 159 to facilitate translation of the driving force of the motor 156, through the gear mechanism within the housing 101, to the gear mechanism within the housing 142. As the gear mechanism within the housing 142 is rotated, the shaft 143 is rotated to operate the distributing device 141, as previously discussed.

As shown in FIGS. 4 and 5, a support arm 162 extends horizontally from the vertical stand 56 and supports a pair of spaced flanges 163-163. A shaft 164 is mounted for rotation between the flanges 163-163 and supports a contact finger 166 which is movable into a position to float on the steel tape 27 on the supply reel 61 shown to the right in FIG. 5. A handle 167 is also secured for rotation with and extends radially from the shaft 164 and facilitates manual rotation of the shaft so that the contact finger 166 may be moved into or out of engagement with the steel tape 27 on the associated reel 61 to detect a depleted reel.

The bases of the winding portions of the reels 61-61 are provided with a paper wrapping (not shown). When the tape rewinding operation is initiated, the contact finger 166 is positioned in engagement with the steel tape 27 supported on the associated reel 61. An electrical circuit (not shown), which controls the operation of the electric motor 156 to facilitate the tape rewinding operation, in-

, cludes a circuit which is completed by the engagement of the contact finger 166 with the steel tape 27 on the associated reel 61 so that the completed circuit facilitates operation of the motor. When the steel tape 27 on the associated reel 61 is depleted, the contact finger 166 engages the paper wrapping on the base of the associated reel 61 so that the circuit for controlling the operation of the electric motor 156 is opened to stop the tape rewinding operation.

Another support arm 168 extends horizontally from the opposite side of the vertical stand 56 in alignment with the support arm 162. The arm 168 supports a pair of spaced flanges 169-169. A shaft 171 is supported for rotation between the flanges 169-169 and further supports a contact finger 172 which can be positioned to float on the steel tape 27 wound on the associated reel 61 shown to the left in FIG. 5. A handle 173 is secured for rotation with and extends radially from the shaft 171 to facilitate manual rotation of the shaft so that the contact finger may be displaced during the removal of a depleted reel 61 and the mounting of a full reel. The contact finger 172 functions in the same manner as the contact finger 166 and facilitates further the control of the electric motor 156 during the tape rewinding operation.

As viewed in FIG. 5, an L-shaped bracket 174 is supported on top of the gear housing 101. A rotatable shaft 176 extends horizontally from the bracket 174 and is supported for rotation relative to the bracket. As further viewed in FIG. 4, a limit switch 177 is mounted on an arm 180 which extends radially from the shaft 176. A handle 178 is secured for rotation with the shaft 176 to facilitate rotation of the shaft so that the switch 177 can be moved out of the path of axial movement of the reel 139.

Subsequent to the assembly of the packaging reels 139-139 on the expandable reel supports 124 and 126, the handle 178 is manipulated to rotate the shaft 176 so that the switch 177 is located in a position spaced from and adjacent to the tape-receiving portion of the reel 139 viewed to the right in FIG. 5. Subsequently, the steel tape 27 is taken up on the associated reel 139 to a desired package level. As the desired level of steel tape 27 is approached, the steel tape on the associated reel 139 engages the limit switch 177 which is connected in the electrical control circuit for the electric motor 156. As the steel tape 27 engages the switch 177, the switch is opened to stop the motor 156 and preclude further operation of the differential tape rewinder 49. Since the steel tapes 27-27 on the associated reels 139-139 are packaged in proportion to the ratio of the pitch diameters of the associated rolls 109 and 112, only one packaging unit need be monitored for attainment of the desired package level. The level of steel tape 27 on the other reel 139 will automatically be at the desired level in view of the differential manner of packaging.

Operation of the difierential tape rewinder Referring to FIG. 5, a pair of the split reel sections 136 and 137 are mounted on each of the conventional reel supports 124 and 126, as previously discussed.

A pair of the full supply reels 61-61 are mounted on the conventional reel supports 59-59 which are supported by the shaft 58. The conventional expandable reel supports 59-59 are adjusted to support for rotation the associated reels 61-61. Referring to FIG. 5, the leading end of the steel tape 27 wound on the reel 61, which is shown to the right, is pulled from the reel and passed over the sheaves 92 and 98. Thereafter, the leading end of the steel tape 27 is passed around the spaced roll 109 and the idler sheave 116 so that the tape is guided through the grooves 111-111 and 117-117, respectively. The leading end of the steel tape 27 is then drawn from the roll 109 and secured to the base of the winding portion of the associated packaging reel 139 which is supported on the expandable reel support 124.

The leading end of the steel tape 27 supported on the full supply reel 61, shown to the left in FIG. 5, is drawn from the reel and passed over the sheaves 93 and 97 and is thereafter wrapped around the spaced roll 112 and the idler sheave 119 so that the tape passes through the grooves 113-113 and 121-121, respectively. The steel tape 27 is then drawn from the roll 112 and attached to the base of the winding portion of the associated packaging reel 139 which is supported on the expandable reel support 126.

Thereafter, the handles 167 and 173 are manipulated to position the contact fingers 166 and 172, respectively, in engagement with the steel tapes 2727 of the associated supply reels 61-61. Further, the handle 178 is manipulated to position the limit switch 177 in a position to detect when the steep tape 27 reaches a desired level on the reel 139 supported on the expandable reel support 124.

The motor 156 is then operated to provide a driving force for the differential tape rewinder 49. Upon operation of the motor 156, the gear mechanism within the gear housing 101 is rotated so that the tubular shaft 122 is rotated. As the tubular shaft 122 is rotated, the pinions 131 and 132 of the differential gear mechanism 129 are orbited about the axis of the tubular shaft. As the pinions 131 and 132 orbit about the tubular shaft 122, a moving force is imparted to the bevel gears 133 and 134 which are in mesh with the pinions 131 and 132. Since the bevel gears 133 and 134 are secured to the expandable reel supports 124 and 126, respectively, the reel supports will rotate about the common axis of the tubular shaft 122 so that the supported reels 139-139 are also rotated to facilitate the takeup of the steel tapes 27-27 onto the associated reels.

As the packaging reels 139-139 are rotated, the steel tapes 2727 are drawn from the associated supply reels 61-61 and pass partially over the associated differential rolls 109 and 112 whereafter the tapes are payed out from the rolls to the associated packaging reels. Due to the difference in the pitch diameters of the rolls 109 and 112, the steel tape 27 paying out from the larger diameter roll 109 is paying out at a rate faster than the rate of pay out of the steel tape from the small diameter roll 112.

As the steel tapes 27-27 are drawn from the associated supply reels 61-61, the supply reels are rotated whereby the pulleys 82 and 84 are also rotated. The rotational movement of the pulleys 82 and 84 is coupled to the pulleys 77 and 78, respectively, through the endless belts 83 and 86, respectively. As the pulleys 77 and 78 rotate freely about the shaft 66, the bevel gears 74 and 76, respectively, of the differential gear mechanism 69 also rotate freely about the shaft 66. As noted previously, the gears 74 and 76 are meshed with the beveled pinions 71 and 72 and orbit the pinions 71 and 72 about the axis of the shaft 66. Since the pinions 71 and 72 are coupled to the spider 73 and the spider is coupled to the shaft 66, the shaft will also rotate.

The brake mechanism within the housing 63 places a dragging force on the rotating shaft 66 in the manner previously described. The dragging force on the shaft 66 is equally divided between the pulleys 77 and 78 and facilitates the application of a uniformly equal torque on the supply reels 61-61 to compensate for the different rates at which the steel tapes 27-27 are being drawn from the associated supply reels.

Since the pay out rate of the steel tape 27 paying over the large diameter roll 109 is greater than the pay out rate of the steel tape paying over the small diameter roll 112, the supply reel 61, shown to the right in FIG. 5, will rotate at a faster rate relative to the supply reel shown to the left. Therefore, the pulley 77 will rotate freely about the shaft 66 at a rate which is faster than the free rotational rate of the pulley 78 about the shaft. Consequently, the bevel gear 74 will rotate faster than the bevel gear 76 so that the pinions 71 and 72 are rotated about their common axis as well as orbited about the axis of the shaft 66. Even though the pulley 77 is rotating at a rate faster than the rotational rate of the pulley 78, the differential gear mechanism 69 compensates for the difference in rotational rates by the rotation of the pinions 71 and 72 to facilitate equal distribution of the dragging force.

As the motor 156 is operated, the gear mechanism within the housing 101 is rotated to facilitate rotation of the tubular shaft 122. As the tubular shaft 122 is rotated, the pinions 131 and 132 are orbited about the axis of the tubular shaft. As the pinions 131 and 132 are orbited about the axis of the tubular shaft 122, the bevel gears 133 and 134 are rotated freely about the tubular shaft. Since the bevel gears 133 and 134 are coupled to the expandable reel supports 124 and 126, respectively, the reel supports will also rotate freely about the tubular shaft 122 so that the packaging reels 139-139 supported on the associated reel supports are rotated about the axis of the tubular shaft.

If the steel tapes 27-27 had not been connected to the base of the winding portions of the associated packaging reels 139--139, the packaging reels would be rotated at identical rotational speeds in accordance with the rate of rotation developed through the gear mechanism within the housing 101. However, the steel tapes are paying out from the rolls 109 and 112 at different individual rates thereby providing the tapes to the associated packaging reels 139-139 at different rates. Consequently, the reels 139-139 must be rotated at different speeds to facilitate the take-up of the associated steel tapes 27-27.

In order to permit the two reels 139--139 to rotate at different speeds while being driven by a common source, the pinions 131 and 132 will rotate about their common axis as well as orbit about the axis of the tubular shaft 122 as the shaft is rotated. The rotation of the pinions 131 and 132 about their common axis permits the bevel gear 133 to rotate faster than the bevel gear 134. This response facilitates the faster rotation of the reel 139, shown to the right in FIG. 5, as compared with the reel shown to the left. Since the rate of pay out of the steel tape 27 from the roll 109 is faster than the pay out of the tape from the roll 112, the differential arrangement of the different diameter rolls controls the rates of rotation of the associated reels 139-139 and the differential gear mechanism 129 permits the different rotational rates of the reels to occur.

Referring now to FIGS. 3 through 6, when the motor 156 is operated, the gear mechanism within the housing 101 rotates the sprocket wheel 160 (FIG. 3) which drives the endless sprocket chain 161 to facilitate rotation of the sprocket wheel 165 (FIG. 3).

Referring particularly to FIG. 6, when the sprocket wheel 165 (FIG. 3) is rotated, the gear mechanism within the housing 142 is rotated to facilitate rotation of the cam 146. As the cam 146 is rotated, the roller 154 follows the contour of the cam and facilitates axial movement of the rod 104 and supports indirectly the different diameter rolls 109 and 112. The pressure applied to the air cylinder 151 through the inlet line 150 is urging constantly the rod 104 to the right, as viewed in FIG. 6, so that the roller 154, which is coupled to the rod, will follow the contour of the cam 146 to provide reciprocating axial movement of the rolls 109 and 112. As the rolls 109 and 112 are reciprocated axially, the steel tapes 27 27 paying out therefrom are distributed onto the rotating packaging reels 139-139.

When the steel tape 27 paying out from the roll 109 reaches a desired level on the associated packaging reel 139, the limit switch 177 is engaged by the steel tape and is operated to stop the motor 156 thereby indicating that the proportionately different lengths of the steel tapes have been packaged on the associated packaging reels. An operator then severs the steel tapes 27-27 in an area between the rolls 109 and 112 and the associated packaging reels 139-139.

In the event either or both of the supply reels 61-61 should become depleted of the steel tapes 27-27, the contact fingers 166 and 172 engage the paper wrapping on the base of the winding portion of the associated reel so that the control circuit for the electric motor 156 is opened to stop the tape rewinding cycle in order that the depleted reel, or reels, may be replaced by a full supply reel, or reels.

TAPE-WRAPPING DEVICE As shown in FIGS. 4 and 5, and particularly in FIG. 7, the tape-wrapping device 48 includes a tubular shaft 181 which is supported at one end thereof by bearings 182 and 183 within the bearing support housing 46. The tubular shaft 181 extends horizontally from the housing 46 and is hollow to facilitate the axial movement of the coaxial unit 21 through the tape-wrapping device 48. A pulley 184 is keyed to an intermediate portion of the tubular shaft 181 and is positioned spatially above another pulley 186 (FIGS. 4 and secured for rotation on the free end of a rotatable shaft 187 extending from a driving motor 188. An endless belt 189 is positioned around the spaced pulleys 184 and 186 to couple the driving force of the motor 188 to the tubular shaft 181.

A pair of brake housings 187 and 188 are mounted spatially axially near the free end of the tubular shaft 181 for free rotation about the shaft and support a pair of electromagnetic brakes 189 and 191, respectively. A pair of brake pads 192 and 193 are mounted spatially axially for rotation with the shaft 181 adjacent to the electromagnetic brakes 189 and 191, respectively.

A pair of expandable reel supports 194 and 196 are mounted on the brake housings 187 and 188, respectively, for rotation with the housings. Each of the reel supports 194 and 196 are provided with cam controlled dogs 197 197 which are adjustable radially to grip the inner walls of the packaging reels 139-139. The packaging reels 139-139 are positioned on the reel supports 1194 and 196 at the tape-wrapping position subsequent to the packaging of the steel tapes 27-27 on the associated packaging reels at the packaging position.

A flyer frame 198 is mounted on an intermediate portion of the tubular shaft 181 for rotation with the shaft. A pair of sheaves 199 and 201 are supported on the flyer frame 198 for rotation about their individual axes and facilitate the unwrapping of the steel tape 27 from the packaging reel 139 shown to the right in FIG. 7. A pair of sheaves 202 and 203 are also supported on the flyer frame 198 for rotation about their individual axes and facilitate the unwrapping of the steel tape 27 from the packaging reel 139 shown to the left in FIG. 7.

The coaxial unit 21 is moved axially through the tubular shaft 181 to facilitate the wrapping helically of the steel tapes 27-27 about the moving coaxial unit 21. The steel tape 27, which is drawn from the associated packaging reel 139 and passed over the sheaves 202 and 203, is passed through alined slots 204 and 206 which are formed in the flyer frame 198 and the tubular shaft 181, respectively. The steel tape 27 passing through the aligned slots 204 and 206 is wrapped helically about the outer tubular conductor 23 of the axially moving coaxial unit 21 to form an inner wrapping of steel tape.

The steel tape 27, which passes over the sheaves 199 and 201, is passed through aligned slots 207 and 208 which are formed in the flyer frame 198 and the tubular shaft 181, respectively. The steel tape 27, which passes through the aligned slots 207 and 208, is wrapped helically on top of the inner wrapping of the steel tape 27 to form an outer wrapping of steel tape. Since the outer wrapping of the steel tape 27 is wrapped on top of the inner wrapping of the steel tape, an additional length of steel tape is required for the outer wrapping to ensure simultaneous depletion of the steel tapes being unwrapped from the packaging reels 139139 at the tape-wrapping position.

As viewed in FIG. 4, the belt 189 also extends around a pulley 209 which is supported for rotation on the end of a shaft 211. The shaft 211 is supported within bearings (not shown) in a frame 212 for rotation relative to the frame. A gear 213 is mounted on an intermediate portion of the shaft 211 for rotation with the shaft. A shaft 214 is supported at one end thereof within a bearing (not shown) in a bearing support housing 216 and is supported at the opposite end thereof in a gear housing 217. A gear 218, which is mounted on and keyed to the shaft 214, meshes with the gear 213 to facilitate rotation of the shaft 214 when the motor 188 is operated. A gear mechanism (not shown), located within the gear housing 217, is rotated when the shaft 214 is rotated and rotates a shaft 219 which extends from the housing and is coupled to the capstan 51. Upon operation of the motor 188, the gear mechanism within the housing 217 facilitates the rotation of the capstan 51 which draws the coaxial unit 21 through the coaxial unit forming machine 28.

As shown in FIGS. 4 and 5, a bracket 221 is secured to the flyer frame 198 adjacent to the sheave 199. A contact finger 222 is supported on the bracket and is positioned 15 on the steel tape 27 of the full packaging reel 139 shown to the right at the tape-wrapping position in FIG. 5. The reel 139, shown to the right at the tape-wrapping position in FIG. 5, is provided with a paper wrapping (not shown) at the base of the winding portion of the reel. The contact finger 222 is included in a control circuit for operating the motor 188. When the supply of steel tape 27 is depleted on the right reel 139 at the tape-wrapping position, the contact finger 222 engages the paper wrapping on the base of the winding portion of the reel so that the control circuit for the motor 188 is opened and the motor is stopped.

Operation of tape-wrapping device Initially, the assembly of the center conductor 22, the spaced, slotted discs 24 and the tubular outer conductor 23 is passed axially through the tubular shaft 181 by the drawing force of the capstan 51. As viewed particularly in FIG. 7, the steel tape 27 is drawn from the packaging reel 139, shown to the left at the tape-wrapping position, and is passed over the sheaves 202 and 203 and further through the slots 204 and 206 to facilitate the wrapping helically of the leading end of the tape about the moving coaxial unit 21 to form the inner wrapping.

The steel tape 27 supported on the packaging reel 139, shown to the right at the tape-wrapping position, is drawn over the sheaves 199 and 201 and is passed through the aligned slots 207 and 208 to facilitate the wrapping helically of the tape about the inner wrapping of the steel tape to form the outer wrapping of the steel tape. To facilitate the wrapping of the steel tapes 2727 about the moving coaxial unit 21, the motor 188 is started to rotate the fiyer frame 198. As the fiyer frame 198 is rotated, the steel tapes 27-27 are pulled from the associated packaging reels 139-139 whereby the tension developed in the tapes between the fiyer frame and the associated reels develops a rotational force applied to the reels so that the brake housings 187 and 188 rotate freely on the tubular shaft 81. As the steel tapes 2727 are drawn from the associated reels 139-139, the reels rotate at a rate slightly faster than the rotational rate of the fiyer frame 198 to facilitate suflicient pay out of the steel tapes to the fiyer frame for the tape-wrapping operation.

During the initial operation of the tape-wrapping device 48, the electromagnetic brakes 189 and 191 may not be operated so that the rotational speed of the full packaging reels 139139 at the tape-wrapping position may be brought up to the desired level. After the desired level of rotational speed is attained by the reels 139-139, the electromagnetic brakes 189 and 191 are operated to establish a tension in the steel tapes 2727 paying off of the reel. As the diameters of the steel tape packages on the reels 139-139 diminish, the electromagnetic brakes 189 and 191 are controlled to increase the braking force on the associated reels so that the tension on the steel tapes 27- 27 paying off from the associated reels is maintained at a substantially constant level.

During the tape-wrapping operation, the reel 139, shown to the left in FIG. at the tape-wrapping position, is rotated at a rate slightly faster than the rotational rate of the fiyer frame 198 to facilitate the pay out of suflicient steel tape 27 to effect the wrapping helically of the tape about the outer tubular conductor 23 of the moving coaxial unit to form the inner wrapping of the steel tape.

The reel 139, shown to the right in FIG. 5 at the tapewrapping position, is also rotated at a rate slightly faster than the rotational rate of the fiyer frame 198 to facilitate the pay out of suflicient steel tape 27 for the wrapping helically of the outer wrapping of the steel tape about the inner wrapping of the steel tape. Since additional steel tape 27 is required for the outer wrapping, the reel 139, as viewed to the right in FIG. 5 at the tape-wrapping position, will rotate slightly faster than the other reel at the tape-wrapping position to facilitate the pay out of the additionally required tape. Hence, the relative rotation between the individual reels 139-139, at the tape-wrapping 1 6 positions, and the fiyer frame 198 is sufficient to facilitate the pay out of the steel tapes 2727 from the associated reels to facilitate the wrapping of the tapes on the moving coaxial unit 21.

In the event it is desired to stop the operation of the tape-wrapping device, the motor 188 is stopped and the electromagnetic brakes 189 and 191 apply a suflicient braking force to the associated reels 139-139 in accordance with the size of the steel tape packages on the associated reels at the instant the tape-wrapping operation is stopped. Since the steel tapes 27 have been packaged differentially on the associated reels 139-139 to facilitate simultaneous depletion, the sensing of the depletion of the steel tape on the reel shown to the right in FIG. 5, at the tape-wrapping position, by the contact finger 222 is also an indication of the depletion of the supply of steel tape on the other reel at the tape-wrapping position. Hence, when the steel tape 27 on the reel 139, shown to the right in FIG. 5 at the tape-wrapping position, is depleted, the tape-wrapping operation will cease. The removal of the empty reels 139-139 and the mounting of full reels at the tape-wrapping position can then be effected.

GENERAL OPERATION Initially, the tape rewinder 49 is used in the manner previously described to wind the steel tapes 2727 onto the associated packaging reels 139-139 at the tapepackaging position. Subsequent to the wrapping of the steel tapes 2727 on the associated reels 139-139 at the packaging position, the expandable reel supports 124 and 126, FIG. 5, are adjusted to release the associated reels.

The full reels 139139, which have been released by the expandable reel supports 124 and 126 at the packaging position, are moved to the left, as viewed in FIGS. 4 and 5, and are supported by a pair of spaced rods 223 and 224, which extend horizontally from the gear housing 101, during the movement of the reels. As shown in FIG. 7, the fully packaged reels 139-439 are positioned on the expandable reel supports 194 and 196 at the tape-Wrapping position where an adjustment to the reel supports is effected to move the cam controlled dogs 197-197 into gripping engagement with the inner walls of the associated reels to support the reels for rotational movement.

Thereafter, the leading end of the center conductors 22 is drawn from the supply reel 32 and is threaded through the disc applicator housing 38 and the tubeforming device 44 which is located within the housing 42. The discs 24 are applied to the center conductor 22 and the outer tubular conductor 23 is formed about the spaced discs coaxially of the center conductor.

Referring to FIGS. 5 and 7, the assembly is passed through the tubular shaft 181 and then through the tubular shaft 122. Referring to FIG. 4, the assembly of the inner and outer conductors 22 and 23 and the discs 24 is wrapped around the capstan 51 and is attached to the take-up reel 52 (FIG. 1) to complete the threading of the leading end of the assembly to facilitate the coaxial unit forming operation.

Subsequent to the threading operation, the motor 54 is operated to rotate the take-up reel 52. In addition, the motor 188 is operated to rotate the capstan 51 in the manner previously described so that the coaxial unit 21 can be drawn through the various operative sections of the coaxial unit forming machine 28.

In addition, operation of the motor 188 initiates the operation of the tape-wrapping device 48 so that the individual steel tapes 2727 are wrapped about the moving coaxial unit 21 in the manner previously described.

During the period when forming of the coaxial unit 21 is occurring, empty reels 139139 are mounted on the expandable reel supports 124 and 126 (FIG. 5) in the manner previously described. Thereafter, a packaging operation is effected at the packaging position to wind proportionately different lengths of steel tapes 2727 on 17 the associated reels 139-439. It is noted that the tape rewinding operation can function independently of the coaxial unit forming operation thereby permitting the tape rewinding operation to be effected simultaneously with the tape-wrapping operation.

The tape rewinding operation can be effected at a much faster rate for a given reel size as compared to the rate of the tape-wrapping operation. Hence, when the supplies of the steel tapes 27-27 on the associated reels 139- 139 at the tape-wrapping position are depleted, the empty :reels are removed by moving the split reel sections 136 associated reels 139139 are then secured to the trailing ends of the steel tapes which extend from the coaxial 'unit 21 and through the flyer frame 198.

The motors 54 and 188 are again operated to continue the operation of the cable unit forming machine 28 in the manner previously described. Subsequently, another tape rewinding operation is effected in preparation for the next shut down period required to replenish the supply of steel tapes 2727 at thetapewrapping position.

It is to be understood that the above-described arrange ments are simply illustrative of the invention. Other arrangement-s may be devised by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.

I claim:

1. A method of packaging simultaneously different lengths of longitudinally extending material, which comprises the steps of:

supplying indefinite lengths of longitudinally extending material, maintaining simultaneously predetermined proportionately different rates of feed of the plurality of individual lengths of longitudinally extending material to a plurality of different associated packages so that at any one instance predetermined proportionately different lengths of the longitudinal material are taken up in the different associated packages, and

supplying the plurality of individual lengths of longitudinally extending material from the plurality of different associated packages at different predetermined rates so that the associated packages will deplete substantially simultaneously.

2. A method of packaging simultaneously different lengths of longitudinally extending material, which comprises the steps of:

supplying a plurality of indefinite lengths of longitudinally extending material, maintaining simultaneously and independently of any packaging of the longitudinal material predetermined proportionately different rates of feed of the plurality of indefinite lengths of longitudinal material, and

packaging simultaneously the indefinite lengths of longitudinally extending material into individual operatively connected packages so that separate packages having predetermined proportionately different lengths of material are formed thereby.

3. A method of packaging simultaneously different lengths of longitudinally extending material, which comprises the steps of:

supplying indefinite lengths of longitudinally extending material,

maintaining simultaneously and independently of any take-up of the longitudinal material predetermined proportionately different rates of feed of the plurality of individual lengths of longitudinally extending material to a plurality of different take-up reels, and

rotating simultaneously and in synchronism the take-up reels at proportionately different rates so that the individual lengths of longitudinally extending material are taken up on the reels and proportionately different lengths of material are packaged on the associated take-up reels.

4. A method of packaging simultaneously different lengths of longitudinal material onto a set of packaging units supported around an axially moving core of indefinite length and for wrapping helically the packaged lengths of longitudinal material around the moving core, which comprises the steps of:

supplying indefinite lengths of longitudinally extending material,

maintaining simultaneously predetermined proportionately different rates of. feed of the plurality of individual lengths of longitudinally extending material to a plurality of different units,

rotating simultaneously the units at proportionately different rates so that the individual lengths of longitudinally extending material are taken up on the units and proportionately different lengths of material are packaged on the associated units, and

unwinding the longitudinal material from the units and Wrapping the individual lengths of longitudinal material from the plurality of units helically onto successive sections of a moving core of indefinite length so that the longitudinal material will be depleted from the units simultaneously.

5. A method of packaging simultaneously different lengths of longitudinal material onto a set of packaging units supported around an axially moving core of indefinite length and for wrapping helically the packaged lengths of longitudinal material around the moving core, which comprises the steps of:

supplying indefinite lengths of longitudinally extending material,

maintaining simultaneously predetermined proportionately different rates of feed of the plurality of individual lengths of longitudinally extending material to alternate sets of Winding units,

rotating the units of each of the sets alternately with the units of each associated set being rotated at proportionately different rates so that the individual lengths of longitudinally extending material are taken up on the units of the associated set and proportionately different lengths of material are packaged on the units of the associated set, and

unwinding the longitudinal material from the units of each of the sets alternately and wrapping the individual lengths of longitudinal material from the plurality of units of the associated set helically onto successive sections of a moving core of indefinite length so that each set of units is used alternately for taking up the different lengths of longitudinal material and as supplies of the different lengths of longitudinal material to be wrapped helically around the moving core.

6. Apparatus for packaging simultaneously different lengths of longitudinally extending material, which comprises:

means for supplying indefinite lengths of longitudinally extending material,

means for taking up onto a plurality of different operatively connected packages individual lengths of the material, and

means for maintaining simultaneously and independent of any take-up of the longitudinally extending material predetermined proportionately different rates of feed of a plurality of individual lengths of the longitudinally extending material so that at any one instance proportionately different lengths of the longitudinally extending material exist in the different operatively connected packages.

7. Apparatus for packaging simultaneously different lengths of longitudinal material, which comprises:

means for paying out simultaneously at different rates and independent of any take-up a plurality of individual lengths of longitudinal material onto a corresponding plurality of take-up units so that proportionately different lengths of the longitudinal material are wound onto the plurality of take-up units, and

means responsive to the different rates of pay out of the individual lengths of longitudinal material for permitting the individual take-up units to be rotated at relatively different rates so that the effective peripheral speed of the take-up unit corresponds to the rate of pay out of the material being taken up on the associated unit and further so that proportionately different lengths of longitudinal material are taken up onto the plurality of take-up units.

8. Apparatus for packaging simultaneously different lengths of longitudinal material onto separate take-up units, which comprises:

a plurality of take-up units,

rotatable means having longitudinal material engaging surfaces positioned in the path of travel of successive sections of a plurality of individual lengths of longitudinal material moving from a plurality of supply units of the individual lengths of longitudinal material to a corresponding plurality of associated take-up units,

the diameters of the surfaces being different with respect to each other,

the longitudinal material of each supply unit being passed at least partially around the associated surface of the rotatable means and onto the associated take-up unit, and

means for rotating each of the take-up units so that the individual lengths of longitudinal material are drawn from the associated supply units and are passed at least partially around the associated surfaces of the rotatable means and rotate the associated surfaces of the rotatable means so that the individual lengths of the longitudinal material are paying out from the associated surfaces of the rotatable means at different rates which are proportional to the difference in the diameters of the surfaces and are taken up onto the associated take-up units at different rates which are determined by the rates of pay out of the individual lengths of the longitudinal material from the associated surfaces whereby different lengths of the longitudinal material are packaged on the associated take-up units.

9. The apparatus as set forth in claim 8, including means for supporting the rotatable means having the different surfaces of different diameters so that the surfaces rotate at the same angular speed to facilitate a difference in the peripheral speeds thereof whereby the successive sections of the longitudinal materials are fed to the associated take-up unit at proportionately different feed rates.

10. The apparatus as set forth in claim 8, wherein the means for rotating the take-up units includes a differential gear mechanism positioned between and coupled to the take-up units to effect a difference in the rotational speed of the take-up units in response to the different rates at which the successive sections of the individual lengths of longitudinal material are being fed from the associated surfaces of the rotatable means to the associated take-up units.

11. The apparatus as set forth in claim 8, including means responsive to the difference in the individual rates of pay out of the successive sections of the individual lengths of longitudinal material from the associated supply units for maintaining the application of a substan- 20 tially constant and equal torque on the supply units regardless of rotational speed changes of the supply units so that the difference in the rates of pay out of the individual lengths of material from the associated supply units are compensated for.

12. The apparatus as set forth in claim 8, including:

a brake device for applying a dragging force to the supply units from which the successive sections of the individual lengths of longitudinal material are being withdrawn, and

means responsive to the difference in the individual rates at which the lengths of longitudinal material are withdrawn from the associated supply units for permitting the dragging force to be applied equally to the plurality of supply units regardless of the different rates of pay out of the individual lengths of material from the associated supply units so that the torque applied to each supply unit is constant and equal.

13. The apparatus as set forth in claim 8, including means for reciprocating the rotating means having the plurality of surfaces as the longitudinal material is passed at least partially therearound so that the material is distributed substantially uniformly across the winding surfaces of the take-up units.

14. Apparatus for packaging simultaneously different lengths of longitudinal material onto a set of packing units supported around an axially moving core of indefinite length and for wrapping helically the packaged lengths of longitudinal material around successive sections of the moving core, which comprises:

a plurality of packaging units,

means for paying out simultaneously at different rates a plurality of individual lengths of longitudinal material from a corresponding plurality of supplies of longitudinal material onto the plurality of packaging units so that proportionately different lengths of the longitudinal material are wound onto the packaging units,

means responsive to the different rates of pay out of the individual lengths of longitudinal material for permitting the packaging units to be rotated at relatively different rates as the units are supported about the path of travel of the core of indefinite length so that the speeds of the winding surfaces of the packaging units correspond to the rates of pay out of the material being packaged on the associated packaging unit and further so that proportionately different lengths of longitudinal material are packaged on the plurality of packaging units, and

means for unwinding the longitudinal material from the packaging units and wrapping the individual lengths of longitudinal material from the plurality of packaging units helically onto successive sections of the moving core of indefinite length with successive lengths of the longitudinal material being wrapped over the preceding lengths to form layers of the wrapped longitudinal material so that the length of longitudinal material required from a successive packaging unit is a predetermined length greater than that required by the preceding packaging unit, the greater predetermined length of longitudinal material required by the succeeding packaging unit resulting from the difference in the diameters of the convolutions of the material wrapped around the core and being controlled by the means for paying out the material at different rates onto the packaging units so that the supplies of the individual packaging units are depleted substantially simultaneously during the unwinding and wrapping operation.

15'. Apparatus for packaging simultaneously different lengths of longitudinal material onto a set of packaging units supported around an axially moving core of indefinite length and for wrapping helically the packaged lengths of longitudinal material around successive sections of the moving core, which comprises:

a plurality of packaging units,

a first means for supporting a plurality of individual 22 that the supplies of the individual packaging units at the wrapping position are depleted substantially simultaneously, the second means for supporting the packaging units at packaging units through which a core of indefinite ceeding packaging unit resulting from the difference in the diameters of the convolutions of the material wrapped around the core and being controlled by the means for paying out the material at difierent rates onto the packaging units at the packaging station so the wrapping position being spaced from the first length is designed to pass, means for supporting the packaging units at the means for paying out simultaneously at dilferent rates packaging position so that a packaging operation of aplurality of individual lengths of longitudinal matelongitudinal material onto packaging units at the rial from a corresponding plurality of supplies of packaging position can be effected during a wrapping longitudinal material onto the plurality of packaging operation of wrapping helically the longitudinal units so that proportionately different lengths of the material from the packaging units onto the moving longitudinal material are wound onto the packaging core of indefinite length as successive sections of the units, core passes the wrapping position.

means responsive to the different rates of pay out of 16. Apparatus for packaging simultaneously different the individual lengths of longitudinal material for lengths of longitudinal material, which comprises: permitting the packaging units to be rotated at elameans for paying out simultaneously at different rates tively different rates as the units are supported about and independent of any take-up a plurality of indi. the path of travel of the core of indefinite lengt 80 vidual lengths of longitudinal material onto a corthat the speeds Of the winding surfaces Of the packagresponding plurality 0f take-up units so that propor. ing units corresp nd to e rates of P y out of the tionately different lengths of the longitudinal matematfllial being Packaged 0n the associated P rial are wound onto the plurality of take-up units, ing unit and further so that proportionately different d lengths of longitudinal material are p g on the means responsive to the different rates of pay out of the plurality of packaging units, individual lengths of longitudinal material for per- Second means for Supporting the plurality of P mitting the individual take-up units to be rotated so aging units at a pp position so that e p that the effective peripheral speeds of the take u rali y f P g g units having the rent leng s units correspond to the rates of pay out of the mate-' of longitudinal material Packaged thereon at the rial being taken up on the associated units and fur- Packaging Position can be moved along the P of ther so that proportionately different lengths of longitrav of t Core ihdfifihite length and SIIPPOrted tudinal material are taken up onto the plurality of at the wrapping position, and take-up units.

means located at the wrapping position for unwinding the longitudinal material from the packaging units References Cited and Wrapping the individual lengths lOIlgitlldiIlfi] P material from the plurality of packaging unit heli- 5 cally onto successive sections of the moving cor of 1,513,583 10/1924 er 5716 XR indefinite length with successive lengths of the longi- 1,830,668 11/1931 ml 5715 tudinal material being wrapped over the preceding 2,462,303 2/ 1949 uget 57-16 l th to form layers of the wrapped longitudinal 2,713,242 7/1955 Esler 57-42 ial so that the length of longitudinal material 40 2,783,608 3/1957 Hasler 57*91 re uired from a successive packaging unit is a prede t ermined length greater than that required by the FOREIGN PATENTS preceding packaging unit, the greater predetermined 308,470 3/1929 Great Britain. length of longitudinal material required by the suc- 855,057 11/1960 Great Britain.

BILLY S. TAYLOR, Primary Examiner.

U.S. Cl. X.R. 

